Electrosurgical instrument

ABSTRACT

An electrosurgical instrument includes an elongated housing having proximal and distal ends. The proximal end is configured to couple to a source of electrosurgical energy via first and second channels extending along a length of the housing to the distal end thereof. The distal end includes a reflector having a dielectric load operably coupled thereto and configured to receive at least a portion of the first conductor therein. In a first mode of operation, electrosurgical energy is transmitted to the first channel and reflected from the reflector to electrosurgically treat tissue. The reflector is configured to receive at least a portion of the second channel therein. In a second mode of operation, electrosurgical energy is transmitted to the second channel to dissect tissue.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patent application Ser. No. 14/954,996, filed on Nov. 30, 2015, now U.S. Pat. No. 9,526,569, which is a continuation application of U.S. patent application Ser. No. 14/564,896, filed on Dec. 9, 2014, now U.S. Pat. No. 9,198,721, which is a continuation application of U.S. patent application Ser. No. 13/477,320, filed on May 22, 2012, now U.S. Pat. No. 8,906,008, the entire contents of each of which are incorporated herein by reference.

BACKGROUND

Technical Field

The present disclosure relates to an electrosurgical instrument. More particularly, the present disclosure relates to a directional microwave energy instrument configured to electrosurgically treat tissue in two modes of operation; a first mode of operation to electrosurgically treat tissue; and a second mode of operation to dissect the tissue.

Description of Related Art

Standard surgical procedures for trauma, cancer and transplants in the kidney, liver, and like organs have several key shortcomings affecting efficacy, morbidity and mortality. In an effort to fully remove or resect an organ, the surgeon may be forced to breach the tissue causing a large amount of bleeding. Careful hemostasis can minimize blood loss and complications but is laborious and time consuming using the systems and methods known in the art. Uncontrollable bleeding, for example, is one of the leading causes that prevent such treatments from being offered to patients with cirrhotic livers.

Typical methods for creating resections and/or controlling bleeding and blood loss include scalpels, electrocautery, ultrasonic scalpels, argon beam coagulators, and radio frequency (RF) surface dissectors. Typically, a surgeon utilizes one of the aforementioned therapies, e.g., a scalpel, for creating resections and another one of the aforementioned therapies, e.g., an argon beam coagulator, to control bleeding. These therapies, however, in their present form have one or more potential drawbacks, such as, for example, a complete lack or partial inability to create a hemostatic or near-hemostatic resection plane with any significant depth (e.g., the devices utilized to control bleeding, typically, create a small footprint).

SUMMARY

As can be appreciated, a directional microwave and radio frequency energy instrument that is configured to electrosurgically treat tissue in two modes of operation to resect and dissect tissue may prove useful in the medical arts.

Embodiments of the present disclosure are described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. As used herein, the term “distal” refers to the portion that is being described which is further from a user, while the term “proximal” refers to the portion that is being described which is closer to a user.

An aspect of the present disclosure provides an electrosurgical instrument. The electrosurgical instrument includes an elongated housing having proximal and distal ends. The proximal end configured to couple to a source of electrosurgical energy via first and second channels extending along a length of the housing to the distal end thereof. The distal end including a reflector having a dielectric load operably coupled thereto and configured to receive at least a portion of the first channel therein. In a first mode of operation electrosurgical energy is transmitted to the first channel and reflected from the reflector to electrosurgically treat tissue. The reflector is configured to receive at least a portion of the second channel therein. In a second mode of operation electrosurgical energy transmitted to the second channel to dissect tissue. The reflector may be formed from a conductive metal tube having a diagonal cross-cut at least partially through a width thereof.

The dielectric load may be shaped to complement a shape of the reflector. The dielectric load may be made from a material including, but not limited to ceramic, fluid and plastic. The dielectric load may include at least one aperture therein that is configured to receive at least a portion of the coaxial feed therein.

In certain instances, the first channel is in the form of a coaxial feed that includes an outer conductor, a dielectric extending past the outer conductor and an inner conductor extending past both the outer conductor and dielectric. In this instance, the inner conductor does not extend past the reflector.

In certain instances, the second channel may be in the form of an electrical lead including a monopolar electrode. In this instance, the monopolar electrode may be disposed at a distal tip of the reflector.

In certain instances, the electrosurgical instrument may also include a microwave block that is operably coupled to the distal end of the electrosurgical instrument adjacent the dielectric load. In this particular instance, the microwave block includes a dielectric distal portion and a conductive proximal portion. The microwave block may be configured to prevent electrosurgical energy from exiting a distal side of the reflector when the electrosurgical instrument is in the first mode of operation. The dielectric portion of the microwave block may include a dielectric constant that is less than a dielectric constant of the dielectric load of the distal end.

In certain instances, the electrosurgical instrument may also include a switch assembly that is supported on the housing and configured to place the electrosurgical instrument into the first and second modes of operation.

In certain instances, the electrosurgical instrument may also include a cooling assembly that operably couples to the electrosurgical instrument and circulates at least one coolant through the electrosurgical instrument to prevent the reflector and electrode from exceeding a predetermined temperature.

In certain instances, the electrosurgical instrument may also a sensor assembly that is configured to detect when the electrosurgical instrument contacts tissue. In this instance, the sensor assembly may be an optical sensor assembly, electrode impedance sensor assembly and acoustic transducer response assembly.

An aspect of the present disclosure provides an electrosurgical instrument. The electrosurgical instrument includes an elongated housing having proximal and distal ends. The proximal end is configured to couple to a source of electrosurgical energy via first and second channels extending along a length of the housing to the distal end thereof. A switch assembly is supported on the housing and is configured to place the electrosurgical instrument into first and second modes of operation. A reflector operably disposed at the distal end of the housing has a tapered configuration and is configured to provide an energy pattern in tissue proportional to a depth of the taper of the reflector. A dielectric load is shaped to complement a shape of the reflector for coupling the dielectric load to the reflector. The dielectric load is configured to receive at least a portion of the first channel therein. In the first mode of operation electrosurgical energy transmitted to the first channel is reflected from the reflector to electrosurgically treat tissue. The reflector is configured to receive at least a portion of the second channel therein. In the second mode of operation electrosurgical energy transmitted to the second channel to dissect tissue.

The dielectric load may be made from a material including, but not limited to ceramic, fluid and plastic. The dielectric load may include at least one aperture therein that is configured to receive at least a portion of the coaxial feed therein.

In certain instances, the first channel may be in the form of a coaxial feed that includes an outer conductor, a dielectric extending past the outer conductor and an inner conductor extending past both the outer conductor and dielectric. In this instance, the inner conductor does not extend past the reflector.

In certain instances, the second channel may be in the form of an electrical lead including a monopolar electrode. In this instance, the monopolar electrode may be disposed at a distal tip of the reflector.

In certain instances, the electrosurgical instrument may also include a microwave block that is operably coupled to the distal end of the electrosurgical instrument adjacent the dielectric load. In this particular instance, the microwave block includes a dielectric distal portion and a conductive proximal portion. The microwave block may be configured to shape electrosurgical energy exiting a distal side of the reflector and improve efficiency of the electrosurgical instrument when the electrosurgical instrument is in the first mode of operation. The dielectric portion of the microwave block may include a dielectric constant that is less than a dielectric constant of the dielectric load of the distal end.

BRIEF DESCRIPTION OF THE DRAWING

Various embodiments of the present disclosure are described hereinbelow with references to the drawings, wherein:

FIG. 1 is a schematic view of an electrosurgical system configured for use with an electrosurgical instrument according to an embodiment of the present disclosure;

FIG. 2 is a schematic, exploded view of a distal end of the electrosurgical instrument depicted in FIG. 1 showing components separated;

FIG. 3 is a schematic, side view of a coaxial feed and dielectric material of FIG. 2 in an assembled configuration;

FIG. 4 is a schematic, side view of the coaxial feed, dielectric material and a reflector of FIG. 2 in an assembled configuration;

FIG. 5a is a schematic, proximal view of an optional microwave balun that may be utilized with the electrosurgical instrument depicted FIG. 1;

FIG. 5b is a schematic, cross-sectional view of the microwave balun depicted in FIG. 5 a;

FIG. 6 is a schematic, side view of the distal end of the electrosurgical instrument depicted FIG. 1 with the microwave balun depicted in FIGS. 5a and 5b operably coupled thereto; and

FIG. 7 is a schematic, bottom view of the reflector depicted in FIG. 2.

DETAILED DESCRIPTION

Detailed embodiments of the present disclosure are disclosed herein; however, the disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.

As noted above, it may prove useful in the medical field to provide a directional microwave and radio frequency energy instrument that is configured to electrosurgically treat tissue in two modes of operation to resect and dissect tissue. In accordance with the instant disclosure, an electrosurgical instrument that couples to an electrosurgical energy source is configured to function in two or more modes of operation, a first mode that provides microwave energy to coagulate tissue (e.g., control bleeding) and a second mode that provides radio frequency energy to dissect the coagulated tissue (e.g., create a resection). The electrosurgical device in accordance with the instant disclosure allows a surgeon to perform both of these procedures with a single instrument.

Turning now to FIG. 1, an electrosurgical system 2 is illustrated including an electrosurgical energy source, e.g., a generator 4, and an electrosurgical instrument 6 in accordance with the instant disclosure.

Generator 4 is configured to generate electrosurgical energy in the form microwave energy and radio frequency energy. In embodiments, the generator 4 may be configured to also generate ultrasonic energy, thermal energy, etc. In accordance with the instant disclosure, frequencies of operation of the generator 4 range from about 915 MHz to about 8000 MHz. Other frequencies of operation of the generator 4 may be below 915 MHz and above 8000 MHz. One or more switches or buttons 8 (shown in phantom in FIG. 1) may be provided on the generator 4 to allow a surgeon to switch between first and second modes of operation. Alternately, and as in the illustrated embodiment, the electrosurgical instrument 6 may include one or more switches 10 (FIG. 1) thereon to allow a surgeon to switch between first and second modes of operation. Or, in certain instances, a footswitch (not explicitly shown) in operative communication with the generator 4 and/or the electrosurgical instrument 6 may be utilized to provide the aforementioned switching capabilities.

Electrosurgical instrument 6 includes a housing 3 having proximal and distal ends 5 and 7, respectively (FIG. 1). Housing 3 may be made from any suitable material including metal, plastic composite, ceramic, etc. In the illustrated embodiment, housing 3 is made from plastic composite. Housing 3 supports switching assembly 10 (and operative components associated therewith) thereon to provide the electrosurgical instrument 6 with hand-held capabilities, e.g., hand-held switching capabilities (FIG. 1).

Switching assembly 10 includes push-buttons 10 a and 10 b that respectively place the electrosurgical instrument 6 into the first and second modes of operation upon activation thereof.

Continuing with reference to FIG. 1, a cable 12 or the like couples the generator 4 to a housing 3 of the electrosurgical instrument 6 to provide electrosurgical instrument 6 with the capability of operating in the first and second modes of operation. To this end, cable 12 couples to proximal end 5 of housing 3 and includes a first channel in the form of a coaxial feed 14 and a second channel in the form of an electrical lead 16 (FIG. 2).

Coaxial feed 14 is received at the proximal end 5 (FIG. 1) of the housing 3 for providing microwave energy thereto and includes an outer sheath (not explicitly shown), an outer conductor 18, a dielectric 20 that extends past the outer conductor and an inner conductor 22 that extends past both the outer conductor 18 and dielectric 20, as best seen in FIG. 2. This configuration of the coaxial feed 16 facilitates coupling the coaxial feed 14 to a dielectric load 24 (FIG. 2), as will be described in greater detail below.

Electrical lead 16 is received at the proximal end 5 (FIG. 1) of the housing 3 for providing radio frequency energy thereto and includes one or more electrodes, e.g., one or more monopolar electrodes 26, at a distal end thereof (FIG. 2).

Both of the coaxial feed 14 and electrical lead 16 extend along a length of the electrosurgical instrument 6 for coupling to the dielectric load 24 and a reflector 28, respectively (FIG. 2).

Referring to FIG. 2, dielectric load 24 is illustrated. Dielectric load 24 may be made from any suitable dielectric material including, but not limited to ceramic, plastic composite, fluid, etc. In the illustrated embodiment, dielectric load 24 is made from ceramic. Dielectric load 24 is shaped to complement the reflector 28 to facilitate coupling the dielectric load 24 to the reflector 28 during the manufacturing process of the electrosurgical instrument 6. The dielectric load 24 is coupled to the reflector 28 via one or ore suitable coupling methods. In the illustrated embodiment, a friction-fit or press-fit is utilized to couple the dielectric load 24 to the reflector 28. In particular, the reflector 28 includes a generally tubular configuration with a diameter that allows the dielectric load 24 to slide into the reflector 28 such that the dielectric load 24 is secured to the reflector 28.

Dielectric load 24 includes a substantially solid configuration with an aperture 30 that is sized to receive the dielectric 20 and the inner conductor 22 therein, see FIGS. 2 and 3. In an assembled configuration, the dielectric 20 and inner conductor 22 are slid into the reflector and positioned adjacent a tapered, diagonal cut that extends along a distal face 32 of the reflector 28 (FIGS. 2-4 and 6). Positioning the inner conductor 22 at this location within the reflector 28 provides an energy pattern that is as long as the tapered distal face of the reflector 28, as best seen in FIG. 6.

Reflector 28 may be made from any suitable conductive material and, as noted above, includes a generally tubular configuration. In the illustrated embodiment, reflector 28 is made from metal that exhibits reflective properties to reflect the microwave energy in accordance with the instant disclosure. A tapered, diagonal cross-cut is provided through a width of the reflector 28 at the distal face 32 thereof. An angle of the cross-cut may be altered to achieve specific energy patterns that are reflected from the reflector 28 to electrosurgically treat tissue. In some embodiments, the reflector 28 may be configured to provide an energy pattern in tissue that is proportional to a depth of the taper of the reflector 28. Further, in certain instances, the distal face 32 may be selectively coated with conductive patterning to facilitate dissecting tissue during the second mode of operation.

Reflector 28 is configured to receive the electrical lead 16 including monopolar electrode(s) 26 therein, e.g., through an aperture (not explicitly shown) that extends through the reflector 28, such that the monopolar electrode(s) 26 is positionable adjacent a distal tip of the reflector 28 to emit radio-frequency energy to dissect tissue in the second mode of operation. Electrode(s) 26 may be secured within the aperture and to the reflector 28 via a press-fit, friction-fit, adhesive or other suitable coupling method.

Reflector 28 may be configured for coupling to the housing 3 by any suitable methods. In the illustrated embodiment, the reflector 28 is overmolded to the housing 3. Alternately, the reflector 28 may be press-fit or friction-fit to the housing 3, or an adhesive may be utilized to couple the reflector 28 to the housing 3.

In embodiments, an optional microwave balun, e.g., a microwave block, choke short, impedance matching network of the like, (FIGS. 5A and 5B) may be operably coupled to a proximal end of the reflector 28 adjacent the dielectric load 24 (FIG. 6). In the illustrated embodiment, the microwave balun is in the form of a microwave block 34 that is configured to keep electrosurgical energy from exiting a distal side of the reflector 28 and control a shape of the radiating field emitted from reflector 28. Microwave block 34 may be configured to a fraction number of wavelengths, e.g., 214 wavelength. Microwave block 34 includes a generally elongated, annular configuration having a distal dielectric portion 36 and a proximal conductive portion 38 (see FIGS. 5A-5B). Distal dielectric portion 36 includes a dielectric that is lower than the dielectric load 24 and includes a higher loss factor than the dielectric load 24. In an assembled configuration the coaxial feed 14 is feed through the microwave block 34 such that the outer conductor 18 is in electrical communication with the proximal conductive portion 38, as best seen in FIG. 6. Configuring the distal dielectric portion 36 in this manner facilitates reducing the overall quality factor “Q” of the electrosurgical instrument 6.

Operation of the electrosurgical instrument 6 is described in terms of a liver resection. In use, electrosurgical instrument 6 is positioned adjacent tissue of interest, e.g., liver tissue. A surgeon may coagulate the tissue via pressing the push-button 10 a to place the generator 4 in the first mode of operation. The microwave energy transmitted to the inner conductor 22 is reflected from the reflector 28 to electrosurgically treat the tissue. The reflective microwave energy provides a precise “footprint” on tissue, e.g., deeply penetrates tissue. The depth that the microwave energy penetrates tissue is determined by, inter alia, the angle of the distal face 32, frequency of operation and/or the power level that the generator 4 is set to.

A surgeon may, subsequently, dissect the electrosurgically treated tissue via pressing the push-button 10 b to place the generator 4 in the second mode of operation. The microwave energy transmitted to the electrode(s) 26 is emitted therefrom to electrosurgically treat the tissue.

The electrosurgical instrument 6 overcomes the aforementioned shortcomings that are typically associated with conventional therapies for resection and dissecting tissue. That is, a surgeon can quickly and effectively resect and dissect tissue with a single instrument. As can be appreciated, this decreases blood loss and the time a patient needs to be under anesthesia during a resection and/or dissection procedure.

From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. For example, in certain embodiments, a cooling assembly 50 (shown in phantom in FIG. 1) may be operably coupled to the electrosurgical instrument 6 and configured to circulate at least one coolant through the electrosurgical instrument 6 to prevent the reflector 28 and/or electrode(s) 26 from exceeding a predetermined temperature.

In certain instances, the electrosurgical instrument 6 may also include surface contact detection capabilities configured to ensure that the electrosurgical instrument 6 is in adequate contact with tissue prior to enabling microwave and/or radio frequency energy to treat tissue. Surface contact capabilities may be provided by any suitable methods, such as, for example, a sensor assembly 52 (FIG. 1 shows a sensor assembly 52 in phantom for illustrative purposes) that is configured to detect when the electrosurgical instrument 6 contacts tissue. In this instance, the sensor assembly 52 may include one or more sensors (or combination of sensors) including, but not limited to, an optical sensor assembly, electrode impedance sensor assembly and acoustic transducer response assembly, etc.

While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

What is claimed is:
 1. A method of assembling an electrosurgical instrument, comprising: disposing a balun about a distal end portion of a coaxial feed that is configured to couple to a source of electrosurgical energy; and operably coupling an electrically conductive reflector to the distal end portion of the coaxial feed, the reflector configured to radiate electrosurgical energy provided by the coaxial feed to treat tissue.
 2. The method according to claim 1, further comprising sliding the coaxial feed into the reflector.
 3. The method according to claim 1, further comprising positioning an inner conductor of the coaxial feed and a dielectric of the coaxial feed adjacent a diagonal surface of the reflector.
 4. The method according to claim 3, further comprising coating the diagonal surface with conductive patterning.
 5. The method according to claim 1, further comprising coupling a dielectric load to the distal end portion of the coaxial feed.
 6. The method according to claim 5, further comprising disposing the distal end portion of the coaxial feed in an aperture defined in the dielectric load.
 7. The method according to claim 5, further comprising disposing the dielectric load in a channel defined in the reflector.
 8. The method according to claim 1, further comprising disposing a monopolar electrode at a distal end portion of the reflector.
 9. The method according to claim 1, further comprising electrically coupling a conductive portion of the balun to an outer conductor of the coaxial feed.
 10. The method according to claim 1, further comprising sliding the coaxial feed through the balun.
 11. A method of assembling an electrosurgical instrument, comprising: coupling a dielectric load to a distal end portion of a coaxial feed; coupling an electrically conductive reflector to the dielectric load, the reflector configured to reflect electrosurgical energy provided by the coaxial feed to treat tissue; and positioning an inner conductor of the coaxial feed and a dielectric of the coaxial feed adjacent a diagonal surface of the reflector.
 12. The method according to claim 11, further comprising disposing the distal end portion of the coaxial feed in an aperture defined in the dielectric load.
 13. The method according to claim 11, further comprising disposing the dielectric load in a channel defined in the reflector.
 14. The method according to claim 11, further comprising coating the diagonal surface with conductive patterning.
 15. The method according to claim 11, further comprising disposing a monopolar electrode at a distal end portion of the reflector.
 16. The method according to claim 11, further comprising operably coupling a microwave block to a proximal end portion of the reflector.
 17. The method according to claim 16, further comprising sliding the microwave block into the proximal end portion of the reflector.
 18. The method according to claim 16, further comprising sliding the coaxial feed through the microwave block.
 19. The method according to claim 16, wherein a dielectric portion of the microwave block includes a dielectric constant that is less than a dielectric constant of the dielectric load.
 20. A method of assembling an electrosurgical instrument, comprising: coupling a dielectric load to a distal end portion of a coaxial feed; coupling an electrically conductive reflector to the dielectric load, the reflector configured to reflect electrosurgical energy provided by the coaxial feed to treat tissue; and disposing a monopolar electrode at a distal end portion of the reflector. 